Equipment reliability is key to maintaining production in chemicals plants, says electrical engineering company Delba Electrical marketing spokesperson Mike Lerios.

Amid South Africa’s constrained and irregular electricity supply, common power interruptions and fluctuations place additional stress on motors, pumps and other critical assets, increasing the risk of failures during restarts and load changes.

“Highly reliable, well-maintained equipment helps plants recover faster after outages, operate safely under unstable power conditions and minimise costly unplanned shutdowns. This, in turn, helps to protect production continuity, product quality and operational profitability,” he adds.

Delba Electrical’s rotating machine repair and maintenance services assist chemicals and petrochemicals plants in improving energy efficiency by restoring motors and rotating equipment to optimal operating condition.

“Through precision rewinding, correct bearing selection, accurate alignment and dynamic balancing, we help reduce electrical losses, mechanical drag and vibration that lead to unnecessary energy consumption,” he says.

Lerios explains that proper inspection and testing ensure that motors operate at the right load and efficiency levels: “By extending equipment life and improving reliability, plants are able to achieve lower operating costs, improved uptime and measurable energy savings across their operations.”

Bearing failure is probably the most common cause of motor and rotating equipment failure in process industries.

“These failures are often as a result of poor lubrication, contamination or misalignment. Misalignment between the motor and driven equipment increases mechanical stress, vibration and energy losses. On the other hand, imbalance in rotating components contributes to excessive vibration and premature wear,” he adds.

Insulation Breakdown

On the electrical side, winding insulation breakdown caused by heat, contamination, voltage imbalance or age is also a frequent problem, Lerios says.

“Overloading and improper operating conditions, such as frequent starts, stalled loads or running outside design parameters, also increases the number of failures. In harsh environments, contamination from dust, chemicals, moisture or corrosive vapours can degrade both mechanical and electrical components.”

In addition, a lack of proper maintenance practices often turns minor issues into major breakdowns, he warns.

Advanced technologies – such as condition monitoring, vibration analysis and electrical and mechanical testing – support predictive maintenance in energy-intensive facilities, thereby reducing the risk of poor maintenance practices.

“By continuously assessing the health of electrical rotating machines, these tools enable Delba Electrical’s specialists to detect early signs of misalignment, wear or electrical faults before failure occurs.”

This data-driven approach allows for proactive maintenance planning. 

“In this way, we can reduce unplanned downtime, extending equipment life and improving overall energy efficiency and reliability in demanding industrial environments,” Lerios concludes.